RECHARGEABLE ENERGY STORAGE SYSTEM OF A VEHICLE WITH STRUCTURAL VENTILATION DUCT

Abstract

A vehicle's rechargeable energy storage system (RESS) comprises a multitude of battery cells. The multitude of battery cells includes a multitude of vent channels to remove hot exhaust gas from the multitude of battery cells. A cell bridge is arranged above the multitude of vent channels. The cell bridge comprises a wire mesh and a plastic material. A vehicle comprises a vehicle body, a powertrain located within the vehicle body, and a rechargeable energy storage system (RESS) that is functionally connected to the powertrain. The RESS comprises a multitude of battery cells, and the multitude of battery cells includes a multitude of vent channels to remove hot exhaust gas from the multitude of battery cells. A cell bridge is arranged above the multitude of vent channels. The cell bridge comprises a wire mesh and a plastic material.

Description

[0001] The present invention relates to vehicles and, in particular, a rechargeable energy storage system (RESS) for a vehicle, according to the preamble of claim 1, as is known essentially from US 2021 / 0 074 960 A1. Comparable energy storage systems are disclosed in US 2021 / 0 359 372 A1, CN 2 19 873 846 U and WO 2024 / 010 332 A1. Further prior art is disclosed in DE 10 2023 109 754 A1.

[0002] Many vehicles incorporate RESS structures to, for example, supply power to the vehicle's drive systems. RESS structures typically comprise a multitude of battery cells arranged as a battery pack within a housing that includes a cover. Under certain conditions, the battery cells can release high-temperature gas (i.e., vent gas from a battery cell) and particles. In some configurations, it is desirable to structurally connect the battery pack to the cover to support it. However, it is also necessary to vent the high-temperature gas from the battery pack and remove any particle residue from the battery pack during a high-temperature event. SUMMARY

[0003] According to the invention, a rechargeable energy storage system (RESS) of a vehicle is presented, characterized by the features of claim 1.

[0004] The array of battery cells incorporates numerous vent channels to remove hot exhaust gases. A cell bridge is positioned above these vent channels. The cell bridge comprises a wire mesh and a plastic material.

[0005] In addition to one or more of the features described herein, the plastic material is designed to melt when exposed to temperatures exceeding 150 degrees Celsius.

[0006] In addition to one or more of the features described herein, the wire mesh is designed to retain particles larger than a specified threshold size in a venting channel defined between the cell bridge and the plurality of battery cells.

[0007] In addition to one or more of the features described herein, the specified threshold size is an effective diameter of 0.9 millimeters.

[0008] In addition to one or more of the features described herein, the cell bridge is connected to and supports a cover of the RESS.

[0009] In addition to one or more of the features described herein, the cell bridge is attached to the cover via an adhesive layer.

[0010] In addition to one or more of the features described herein, the wire mesh is made of steel.

[0011] In addition to one or more of the features described herein, a multitude of leg openings are formed in the plastic material.

[0012] In addition to one or more of the features described herein, the wire mesh material extends through the multitude of leg openings.

[0013] In addition to one or more of the features described herein, the cell bridge is formed by overmolding the wire mesh with the plastic material.

[0014] In another exemplary embodiment, a vehicle comprises a vehicle body, a powertrain arranged in the vehicle body, and a rechargeable energy storage system (RESS) functionally connected to the powertrain. The RESS comprises a plurality of battery cells, and the plurality of battery cells comprises a plurality of vent channels for dissipating hot exhaust gas from the plurality of battery cells. A cell bridge is arranged above the plurality of vent channels. The cell bridge comprises a wire mesh and a plastic material.

[0015] In addition to one or more of the features described herein, the plastic material is designed to melt when exposed to temperatures exceeding 150 degrees Celsius.

[0016] In addition to one or more of the features described herein, the wire mesh material is designed to retain particles larger than a specified threshold size in a venting channel defined between the cell bridge and the plurality of battery cells.

[0017] In addition to one or more of the features described herein, the specified threshold size is an effective diameter of 0.9 millimeters.

[0018] In addition to one or more of the features described herein, the cell bridge is connected to and supports a cover of the RESS.

[0019] In addition to one or more of the features described herein, the cell bridge is attached to the cover via an adhesive layer.

[0020] In addition to one or more of the features described herein, the wire mesh is made of steel.

[0021] In addition to one or more of the features described herein, a multitude of leg openings are formed in the plastic material.

[0022] In addition to one or more of the features described herein, the wire mesh extends through the multitude of leg openings.

[0023] In addition to one or more of the features described herein, the cell bridge is formed by overmolding the wire mesh material with the plastic material.

[0024] The aforementioned features and advantages, as well as further features and advantages of the invention, are readily apparent from the following detailed description in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Further features, advantages and details are included only as examples in the following detailed description, which refers to the drawings in which: Fig. 1 is a schematic representation of an embodiment of a vehicle; Fig. 2 is a cross-sectional representation of a rechargeable energy storage system (RESS) of a vehicle with a large number of battery cells; Fig. 3 is a cross-sectional view of an embodiment of a cell bridge of a RESS; Fig. 4 is a perspective view of an embodiment of a cell bridge of a RESS; Fig. 4A is a cross-sectional view of another embodiment of a cell bridge of a RESS; Fig. 4B is a cross-sectional view of yet another embodiment of a cell bridge of a RESS; and Fig. 5 is another cross-sectional view of a vehicle's RESS. DETAILED DESCRIPTION

[0026] The following description is for illustrative purposes only. It is understood that in the drawings, corresponding reference symbols denote identical or equivalent parts and features.

[0027] According to an exemplary embodiment, a vehicle according to an example in Fig. 1, generally referred to as 10. The vehicle 10 comprises a body 12 mounted on a plurality of wheels 16. In one example, two of the plurality of wheels 16 are steerable. The body 12 partially defines a passenger compartment 20 with seats 22 arranged behind an instrument panel 26. A steering control 30 is located between the seats 22 and the instrument panel 26. The steering control 30 is operated to control the orientation of the steerable wheel(s). The vehicle 10 comprises a powertrain, which includes, for example, an electric motor 34 connected to a transmission and which supplies power to one or more of the plurality of wheels 16. A rechargeable energy storage system (RESS) assembly 38 supplies power to the electric motor 34.

[0028] With the following reference to Fig. Figure 2 shows a cross-sectional view of an exemplary embodiment of a RESS assembly 38. The RESS assembly 38 comprises a carrier 42 with a plurality of cells 44 arranged therein. A cover 46 is attached to the RESS assembly 38 to enclose it. As shown in Fig. As shown in Figure 3, a cell bridge 48 is provided between the cells 44 and the cover 46 to structurally support the cover 46 during normal operation of the vehicle 10. The cell bridge 48 spans a vent 50 between a cell head 52 of the battery cell 44 and the cover 46 and comprises two bridge legs 54 extending from the battery cells 44 to a bridge cap 56, which is connected to the cover 46. In some embodiments, such as in Fig. As shown in Figure 4, the cell bridge 48 further comprises one or more bridge bases 60, from which the bridge legs 54 extend.

[0029] The cell bridge 48 is formed from a low-temperature plastic material 62, which is overmolded over a metal wire mesh 64, made, for example, of steel. In some embodiments, the overmolding is carried out by one or more injection molding processes. However, a person skilled in the art will recognize that this method is only exemplary and that other forming processes can also be used. In some embodiments, the wire mesh 64 is also enclosed in the plastic material 62, while in other embodiments, as in Fig. 4A and Fig. 4B, the wire mesh 64 and the plastic material are separate layers that are joined together to form the cell bridge 58.

[0030] The plastic material 62 is designed to melt at temperatures exceeding, for example, 150 degrees Celsius, while the wire mesh 64 is designed to withstand temperatures occurring during a thermal event of the RESS assembly 38, for example, temperatures in the range of 400 to 1200 degrees Celsius. In some embodiments, the entire cell bridge 48 is formed from the wire mesh 64 overmolded with the plastic material 62, while in other embodiments only parts of the cell bridge 48, such as the bridge legs 54 and / or the bridge cap 56, are formed with this configuration. As shown in Fig. As shown in Figure 4, the bridge legs 54 can include one or more leg openings 66 in the plastic material 62, with the wire mesh 64 extending over the leg openings 66 in some embodiments. The leg openings 66 allow for rapid pressure release in the vent channel 50 between the cell bridge 48 and the battery cells 44 in the early stages of a thermal event, so that the plastic material 62 can melt quickly.

[0031] With the following reference to Fig.Figure 5 schematically depicts the cell bridge 48 during a thermal event. In such a case, the plastic material 62 melts away due to the high temperature, and the wire mesh 64 remains between the cover 46 and the cells 44. During a thermal event, the wire mesh 64 allows venting gases 68 to pass through it while simultaneously preventing particles 70 ejected from the battery cells 44 that exceed a pre-selected threshold size from passing through it. In some embodiments, the wire mesh is designed to prevent particles 70 with an effective diameter of, for example, more than 0.9 millimeters from passing through it. Particles 71 smaller than the predetermined threshold size can pass through the wire mesh 64.The wire mesh 64 can be designed to break down larger particles 70, which exceed the threshold size, into particles 71 that do not exceed the threshold size by impacting the particles 70 on the wire mesh 64. Thus, if the plastic material 62 melts during a thermal event, the wire mesh 64 remains in place so that the venting gases 68 can escape and the exit of large particles 70 from the vent channel 50 is prevented. This enclosure reduces the risk of arcing near high-voltage elements of the cells 44.

Claims

[1] Rechargeable energy storage system (38) of a vehicle (10), comprising: a plurality of battery cells (44), wherein the plurality of battery cells (44) comprises a plurality of vent channels (50) for discharging hot vent gas (68) from the plurality of battery cells (44); and a cell bridge (48) arranged above the plurality of vent channels (50), the cell bridge (48) comprising a wire mesh (64) and a plastic material (62); characterized by , that The cell bridge (48) between a cell head (52) of the battery cells 44 and the cover (46) spans a vent channel (50) defined between the cell bridge (48) and the plurality of battery cells (44), the cell bridge (48) comprising two bridge legs 54 extending from the battery cells (44) to a bridge cap (56) connected to the cover (46). [2] Rechargeable energy storage system (38) according to claim 1, wherein the plastic material (62) is designed to melt when exposed to temperatures above 150 degrees Celsius. [3] Rechargeable energy storage system (38) according to claim 1, wherein the wire mesh (64) is configured to retain particles (70) that are larger than a predetermined threshold size in a venting channel (50). [4] Rechargeable energy storage system (38) according to claim 3, wherein the predetermined threshold size is an effective diameter of 0.9 millimeters. [5] Rechargeable energy storage system (38) according to claim 1, wherein the cell bridge (48) is connected to and supports a cover (46) of the rechargeable energy storage system (38). [6] Rechargeable energy storage system (38) according to claim 5, wherein the cell bridge (48) is attached to the cover (46) via an adhesive layer (58). [7] Rechargeable energy storage system (38) according to claim 1, wherein the wire mesh (64) is a steel material. [8] Rechargeable energy storage system (38) according to claim 1, wherein a plurality of leg openings (66) are formed in the plastic material (62). [9] Rechargeable energy storage system (38) according to claim 1, wherein the cell bridge (48) is formed by overmolding the wire mesh (64) with the plastic material (62). [10] Vehicle (10), comprising: a vehicle body (12); a powertrain arranged in the vehicle body (12); and a rechargeable energy storage system (38) according to any one of claims 1 to 9.

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